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Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 1
Gear_Shanghai_2002l_ATK_E_Q_Part1
Industrial Gear Oils
Performance Levels
Reduction of friction
Reduction of the oil sump temperature
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 2
Gear_Shanghai_2002l_ATK_E_Q_Part1
Spur Gear or Straight-Tooth Gear
Helical Gear
Spiral Bevel Gear
Hypoid Gear
rolling Contact (Line)
sliding Motion , Slip
Gear Types – Schematic
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 3
Gear_Shanghai_2002l_ATK_E_Q_Part1
Gear Types – Hansen Transmission
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 4
Gear_Shanghai_2002l_ATK_E_Q_Part1
Gear Types – L+S, Bosch Rexroth
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 5
Gear_Shanghai_2002l_ATK_E_Q_Part1
Gear = Machine part which transmits motion and force from one rotary shaft to another
electrical Energy Pelect mechanical Energy Pmech
mechanical Energy = Moment x Revolutions
Pmech = M1 x n1 = M2 x n2
Moment M1 = Force F1 x Radius r1
Function of Gears - Schematic
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 6
Gear_Shanghai_2002l_ATK_E_Q_Part1
Mechanism of the lubrication
Tribometrie, H Jünemann, Band 547, Expert VerlagTribologie bei der Zahnradschmierung , Dr.-Ing. K Michaelis, TU München, FZG
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 7
Gear_Shanghai_2002l_ATK_E_Q_Part1
Load Carrying Capacity Test for Lubricating Oils
DIN 51354 Part 2, FZG A/ 8,3 / 90A = Particular Tooth Form
•High Sliding Velocity - One-Sided Profile Displacement•Scuffing and Scoring are affected by the Lubricant •Oil Sump Lubrication
PinionWheel
FZG Test - Load Carrying Capacity Test
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 8
Gear_Shanghai_2002l_ATK_E_Q_Part1
Load Carrying Capacity Testfor Lubricating Oils
FZG Gear Test Rig, DIN 51354-2~ CEC L-07-A-85Method A 8,3 / 90
FZG A/ 8,3 / 90A = Particular Tooth FormSpeed at the Pitch Circle 8,3 m/sInitial Oil Temperature 90°Cmax. Load Stage : >12
FZG A/ 16,6 / 140A = Particular Tooth FormSpeed at the Pitch Circle 16,6 m/sOil Temperature 140°Cmax. Load Stage : >12
FZG Test - Load Carrying Capacity Test
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 9
Gear_Shanghai_2002l_ATK_E_Q_Part1
Wear as a result of e.g.: low speedlow viscosityhigh oil temperature / thin film .....
Tooth profile with typical wear on the surface( wear is a continuous procedure, Face of tooth with wear on the tip of the gear tooth and wear on the root of the gear tooth )
Improvement with e.g.:higher viscosityEP/AW additives (chemical and physical )....
Tribometrie, H Jünemann, Band 547, Expert VerlagTribologie bei der Zahnradschmierung , Dr.-Ing. K Michaelis, TU München, FZG
Wear/ Verschleiß on the surface of a tooth
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 10
Gear_Shanghai_2002l_ATK_E_Q_Part1
Tooth profile with typical scuffing marks on the surface (Scuffing/ Fressen = a result of a sudden damage) (normally not in the region of the pitch cicle )
Scuffing as a result of e.g.: middle or high peripheral velocitylocal high stresslocal high pressurecase carburized surface of the toothsudden damage...
Improvement with e.g.:higher viscosityEP/AW additives....
Tribometrie, H Jünemann, Band 547, Expert VerlagTribologie bei der Zahnradschmierung , Dr.-Ing. K Michaelis, TU München, FZG
Scuffing/ Fressen marks on the surface of a tooth
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 11
Gear_Shanghai_2002l_ATK_E_Q_Part1
Comparison of Scuffing / Fressen Wear/ Verschleiß
Tribometrie, H Jünemann, Band 547, Expert VerlagTribologie bei der Zahnradschmierung , Dr.-Ing. K Michaelis, TU München, FZG
Scuffing / Wear
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 12
Gear_Shanghai_2002l_ATK_E_Q_Part1
Micro-Pitting Capacity Test for Gear Lubricants
FVA Research Projects Nr. 54 / I -IV, 1993,GT (GFT) - C/8,3/90; GT (GFT)~ Micro-Pitting-Test C = Particular Tooth Form
•Balanced Sliding Velocity - more in Line with Practice•Influence of Lubricants (Additives) on Micro-Pitting •Spray Lubrication, 2l/min into the Tooth Mesh
Wheel
Pinion
GFT Test - Micro-Pitting Capacity Test
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 13
Gear_Shanghai_2002l_ATK_E_Q_Part1
Micro-Pitting Capacity Testfor Gear Lubricants
FVA Research Projects Nr. 54 / I-IV, 1993,GT (GFT) - C/8,3/90; GT (GFT)~ Micro-Pitting-Test
GFT (GT) , FZG C/ 8,3 / 90C = Particular Tooth FormSpeed at the Pitch Circle 8,3 m/sOil Temperature 90°CSpray Lubricationmax. Load Stage : 10 = high
C = Particular Tooth Form
Micro-Pitting Capacity Test for Gear Lubricants
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 14
Gear_Shanghai_2002l_ATK_E_Q_Part1
Tooth profile with typical Micro Pitting marks on the surface (Micro Pitting is a long term fatigue damage, normally in the root region of the tooth )
Micro Pitting as a result of e.g.: in different peripheral velocity regionscase carburized surface of the toothlong term fatigue damageinfluence of the additives...
Improvement with e.g. :higher viscosity / higher film thicknesslow friction coefficientspecial EP/AW additives....
Tribometrie, H Jünemann, Band 547, Expert VerlagTribologie bei der Zahnradschmierung , Dr.-Ing. K Michaelis, TU München, FZG
Micro Pitting/ Graufleckigkeit marks on the surface of a tooth
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 15
Gear_Shanghai_2002l_ATK_E_Q_Part1
Tooth profile with typical Pitting marks on the surface (Pitting is a long term damage, e.g. in the micro pitting region of the tooth )
Pitting as a result of e.g.: in different peripheral velocity regionscarburized surface of the tooth or tough tempering surface of the toothlong term fatigue damageinfluence of the additives... Improvement with e.g.:
higher viscosity / higher film thicknessSynthetic Oilslow friction coefficientspecial EP/AW additives....
Tribometrie, H Jünemann, Band 547, Expert VerlagTribologie bei der Zahnradschmierung , Dr.-Ing. K Michaelis, TU München, FZG
Pitting / Grübchenbildung marks on the surface of a tooth
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 16
Gear_Shanghai_2002l_ATK_E_Q_Part1
Comparison of Pitting Marks on a
Case carburized tooth( Einsatzgehärtet )
Tough tempering tooth(Vergütet )
Tribometrie, H Jünemann, Band 547, Expert VerlagTribologie bei der Zahnradschmierung , Dr.-Ing. K Michaelis, TU München, FZG
Pitting Marks
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 17
Gear_Shanghai_2002l_ATK_E_Q_Part1
New Additive Technology - RENOLIN
Wear on the tooth flanks of gearsMicro-pitting behaviourFZG C/8,3/90 – FVA No. 54/I-IV
Middle
High
Low
Middle
High
Low
Micro-pittingLoad Stage
Micro-pittingLoad Stage
Old Technology
New RENOLIN
Technology
RENOLIN industrial gear oils pass micro-pitting
tests:
High load stage in- Endurance test- Load stage test
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 18
Gear_Shanghai_2002l_ATK_E_Q_Part1
Test results – Micro-pitting resistance Mean profile deviation at the pinion
(3 different tooth flanks)
0
5
10
15
20
25
5 6 7 8 9 10 8 10 10 10 10 10
mean p
rofile
devia
tion [µ
m] CLP-M
RENOLIN CLP 220
CLP-PGRENOLIN PG 220
CLP-EPLANTOGEAR 220 S
CLPF-MRENOLIN CLPF 220 SUPER
CLP-PAORENOLIN UNISYN CLP 220
5 6 7 8 9 10 8 10 10 10 10 10
795 945 1094 1245 1395 1547 1245 1547 1547 1547 1547 1547
KS
pHmax
Load stage test - 16 h per load stage (KS)
limit: 7,5 m mean profile deviation
Endurance test - 80 h per load stage ( KS)
limit: 20 m mean profile deviation
5
0
10
15
25
20
Pitting
= Hertzian pressure at pitch point
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 19
Gear_Shanghai_2002l_ATK_E_Q_Part1
FE8 – roller bearing wearroller element- and cage material wear, FE8 test rig from FAG, Germany
Wear of the roller elementsWear of the cage material
FAG GermanyFE8 – roller bearing wear
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 20
Gear_Shanghai_2002l_ATK_E_Q_Part1
240
2,6
1
10
100
1000
Old Technology
New RENOLIN CLP
Technology
We
ar
[mg
]
New Additive Technology - RENOLIN
Wear on roller bearing elementsFE8 Test (FAG) – Steel / Steel
D 7,5 / 80-80
V 50% roller
elements
Requirement DIN 51517 – Draft,
Year 2002:Wear of roller
elements max. 30 mg
according to DIN 51819-3
Roller wear [mg]
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 21
Gear_Shanghai_2002l_ATK_E_Q_Part1
Gear Oils
CLP
CL
Industrial Gear Oils
Foodgrade LubricantsAGMA 9005 / D94ISO 6743-6DIN 51515 / DIN 51502
Automotive Gear OilsAPI, GL4, GL5
CLP-HC (PAO)
CLPF (D) CKE – CKB + Frict. Mod.
CKD – R&O, EP/AW, HT
CKB – R&O
CKC – R&O, EP/AW
CKS – Synthetic(AW/EP – light), LT, HT
CLP-PG (PAG)
CLP(D)
CLP-E (Ester)(biodegradable
fluids)
R&O and EP OilsAGMA 2EP – 9EPISO VG 68 - 1500
Synthetic Gear OilsAGMA 0S – 8S
ISO VG 32 - 680
R&O OilsAGMA 0-6:
ISO VG 32 – 320
R&O Oils + Frict. Mod.AGMA 7 Comp – 460AGMA 8 Comp – 680
AGMA 8A Comp - 1000
CKT – Synthetic(AW/EP – high), LT, HT
H1 PAO
H1 USP White Oil
RENOLIN CLP
RENOLIN DTA
R. UNISYN CLP
R CLPF SUPER
RENOLIN PG
R. CLP PLUS
PLANTOGEAR S
Classification of Gear Oils
L = Anti Oxidant, Anti Corrosion = R&OP = Anti-wear, Extreme Pressure = AW/EPD = Detergent / DispersantF = MOS2 (black colour)HT = High TemperatureLT = Low TemperatureFrict. Mod. = Friction Modifier
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 22
Gear_Shanghai_2002l_ATK_E_Q_Part1
RENOLIN Base Oil CL CLP CLPDCLPF
(MoS2)
Extremely High
Oxidation Stability
High Micro-Pitting
Resistance
CL / DTAMineral
OilX
CLPMineral
OilX X X
CLP Plus Mineral
OilX X
X(light DD
properties)A.O. Boaster ! X
CLPF SuperMineral
OilX X
X(light DD
properties)X (X – medium)
RENOLIN – Industrial Gear Oils – Mineral Oil-Based Fluids, (P-S Additives)
L – Anti-Oxidants / Anti-Corrosion AdditivesP – Anti-Wear- / Extreme-Pressure Additives
D – Detergent / Dispersant AdditivesF – Contains MoS2 (black colour)
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 23
Gear_Shanghai_2002l_ATK_E_Q_Part1
Base Mineral Biode- Gear Performance Bearing
OilOil
Compati-grada-bility
FZG PerformanceHigh Micro-
Perfor-mance,
bility A/8,3/90 A/16,6/140 Pitting Resistance
FE8 Test
RENOLIN UNISYN CLP
PAO
CLP-HCYes No > 14 > 12
Pass
= High
Pass
Excellent
RENOLIN PGPAG
CLP-PGNo No > 14 > 12
Pass
= High
Pass
Excellent
PLANTO-GEAR S
POE
CLP-EYes Yes > 14 > 12
Pass
= High
Pass
Excellent
L – Anti-Oxidants / Anti-Corrosion AdditivesP – Anti-Wear- / Extreme-Pressure Additives
HC – Synthetic HydrocarbonsPG – Polyalkylene GlycolsE – Synthetic Ester Oils
RENOLIN – Industrial Gear Oils – Synthetic Fluids, (P-S Additives)
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 24
Gear_Shanghai_2002l_ATK_E_Q_Part1
Industrial Gear Oils – Specialities
Application Performance
RENOLIN MORGEAR Series Morgan Bearings
DANIELI Approval
According to Morgan Specifications
Mild / light EP/AW, good demulsibility
POWERGEAR Series Mining EquipmentGood emulsifying properties
For equipment with high water contamination
RENOLIN SPP UK – Steel Industry
Good emulsifying properties
For equipment with high water contamination
Mild / light EP gear oil
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 25
Gear_Shanghai_2002l_ATK_E_Q_Part1
Industrial Gear Oils DIN 51 502, DIN 51 517, ISO 6743-6, AGMA 9005-D 94
o Mineral Oils, CLP-M: e.g. RENOLIN CLP 220 e.g. RENOLIN CLP 220-PLUS Mainly „standard lubricants“ Universally applicable
o Polyalphaolefins, CLP-PAO: e.g. RENOLIN UNISYN CLP 220 For high operating temperatures Long lifetime Paints + elastomers = no prob- lems Miscible and compatible with mineral oil (ca. 10-20%)
CH3 CH3
CH3 CH3
CH3
CH3 CH3CH3CH3
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 26
Gear_Shanghai_2002l_ATK_E_Q_Part1
Industrial Gear Oils DIN 51 502, DIN 51 517, ISO 6743-6, AGMA 9005-D 94
o Polyglycol, CLP-PG: e.g. RENOLIN PG 220 Low friction coefficients („worm gears“) For high operating temperatures Compatibility with paints and elastomers ?! – Tests are required Not compatible with mineral oil ! High load carrying capacity, good wear protection
o Synth. Ester („Bio“), CLP-E: e.g. PLANTOGEAR 220 S Environmentally friendly Rapidly biodegradable Paints, elastomers ? (compatibility with esters) – Tests are required Low friction coefficients (clutch lamellar coatings) High load carrying capacity, good wear protection
H2C
H3C H2C C
H2C
O
O O
R2CH2
O R3
O
R1
O
RO
OO
OR
CH3
CH3
i j k
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 27
Gear_Shanghai_2002l_ATK_E_Q_Part1
Industrial Gear Oils Comparison of typical base fluid characteristics
Base Oil M. OilMineral oil,
e.g. RENOLIN CLP 220
PAOPolyalphaolefins,
e.g. RENOLIN UNISYN CLP 220
PAGPolyglycol,
e.g. RENOLIN PG 220
POEEsters,
e.g. PLANTO-GEAR 220 S
Viscosity at 40°C [mm2/s] at 100°C [mm2/s]
22018,4
= 100%
22025,7
= 140%
22034,7
= 188%
22028
= 152%
Viscosity index 95 150 200 160
Flashpoint [°C] 230 260 230 280
Pourpoint [°C] -18 -54 -33 -48
Water-soluble no no yes/partly no
P – Pressure-Viscosity-Coefficient at 40°C (ISO VG 100)
M = 1,94/kbar= 100%
PAO = 1,39/kbar= 72%
-- E = 1,25/kbar= 65%
Paints – Compatibility +++ ++ (ester share of ca. 2-5%)
Check! Check!
Elastomers – Compatibility +++ ++ (ester share of ca. 2-5%)
Check! Check!
+++ = very good, ++ = good
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 28
Gear_Shanghai_2002l_ATK_E_Q_Part1
Temperature range
according to: Flender GFT* Blatt 5
Mineral oils, CLP-M: -10°C to 90°C (short periods: 100°C) -15°C to 130°C
Polyglycol, CLP-PG: -20°C to 100°C (short periods: 110°C) -30°C to 180°C
Polyalphaolefins, CLP-PAO: -20°C to 100°C (short periods: 110°C) -45°C to 150°C
Synth. Ester („Bio“), CLP-E: -15°C to 90°C -30°C to 180°C
Lifetime at an average oil temperature of 80°C (according to Flender)
Mineral oils, CLP-M: 2 years or 10.000 h
Synth. Ester („Bio“), CLP-E: 2 years or 10.000 h
Polyglycol, CLP-PG: 4 years or 20.000 h
Polyalphaolefins, CLP-PAO: 4 years or 20.000 h
Contaminations (e.g. water, dirt, abrasion / wear products, acid gases, etc.) have a negative influence on the lifetime.
Temperature range and lifetime of Industrial Gear Oils
* GFT = German Association of Tribology
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 29
Gear_Shanghai_2002l_ATK_E_Q_Part1
Lifetime of Industrial Gear Oilswith regard to the oxidation stability: ISO VG 220
Rotary Bomb Oxidation Test RBOT – ASTM 2272 (2112)
0
0,5
1
1,5
2
2,5
3
3,5
4
Min
era
l Oils
CL
P-M
Min
era
l Oils
CL
P-P
LU
S
Po
lya
lph
a-
ole
fins
CL
P-P
AO
Po
lyg
lyco
ls
CL
P-P
G
Syn
the
tic e
ste
rs
(bio
de
gra
da
ble
)
CL
P-E
0
0,5
1
1,5
2
2,5
3
3,5
4
M.Oil PAO PAG POE
1 2-2,5 3,5-4 2,5-3 1-1,5
Test parameters: 50 g oil5 ml H2O3 m Cu-wireO2 – 620 kPaTemp. 150°C
The period of time is measured in which the oxygen in the autoclave has been used up.
CLP-M: e.g. RENOLIN CLP 220CLP-PLUS: e.g. RENOLIN CLP 220 PLUSCLP-PAO: e.g. RENOLIN UNISYN CLP 220CLP-PG: e.g. RENOLIN PG 220CLP-E: e.g. PLANTOGEAR 220 S
Life
tim
e f
act
or
Wolfgang Bock / FPOC-Industrial Oils / November 2002
Fig. 30
Gear_Shanghai_2002l_ATK_E_Q_Part1
Cost effectiveness
• longer lifetime of synthetic lubricants (factor 2)
• Reduction of the oil sump temperature by ca. 10°C (factor 2)
• Reduction of service, waste oil, stop periods, ... (factor 2)
Compensation of the higher prices by:
0
0,5
1
1,5
22,5
3
3,5
4
4,5
Min
eral
Oils
CLP
-M
Pol
yalp
ha-
olef
ins
CLP
-PA
O
Pol
ygly
cols
CLP
-PG
Syn
thet
ic e
ster
s(b
iode
grad
able
)C
LP-E
Pri
ce f
acto
r
0
0,5
1
1,5
22,5
3
3,5
4
4,5
M.Oil PAO PAG POE
1 3,5-4,5 3-4 3-4
CLP-M: e.g. RENOLIN CLP SeriesCLP-PAO: e.g. RENOLIN UNISYN CLP SeriesCLP-PG: e.g. RENOLIN PG SeriesCLP-E: e.g. PLANTOGEAR S Series
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